ABB TC625

Description

Detailed parameter table

ABB TC625

Product introduction

The TC625 is a high-performance thermocouple input module from ABB, designed to accurately measure temperature in industrial processes using various thermocouple types. As a key component of the S800 I/O system, it converts millivolt signals from thermocouples into digital data for the AC800M controller, enabling precise temperature monitoring and control in applications ranging from high-temperature furnaces to cryogenic systems.

With 8 isolated channels supporting all common thermocouple types, TC625 offers exceptional flexibility for diverse temperature measurement needs. Its built-in cold junction compensation ensures measurement accuracy even as ambient temperatures fluctuate, critical for maintaining process stability in environments like chemical reactors and heat treatment ovens. Whether paired with XVC769AE101 termination units for organized wiring or integrated with AO910 modules for closed-loop temperature control, TC625 delivers reliable performance, making it a staple in industries where temperature precision directly impacts product quality and safety.

Core advantages and technical highlights

Broad thermocouple compatibility

TC625 supports 8 standard thermocouple types, eliminating the need for multiple specialized modules. In a metal processing plant, this versatility allows the same module to measure:

• Furnace temperatures up to 1820°C using Type B thermocouples
• Cooling water temperatures around 50°C with Type K thermocouples

This reduces inventory costs and simplifies spare parts management, while ensuring accurate measurements across the entire temperature spectrum.

Advanced cold junction compensation

The module’s precision cold junction compensation (±0.5°C accuracy) minimizes errors caused by ambient temperature changes. In a pharmaceutical lyophilization (freeze-drying) unit, where temperatures range from -50°C to +30°C, this feature ensures that even small ambient shifts near the module don’t affect measurements of the ultra-low process temperatures, maintaining compliance with strict regulatory requirements.

Channel isolation and diagnostics

Each channel of TC625 features 2.5 kV AC isolation, preventing ground loops and electrical noise from corrupting signals. In a pulp mill with high-voltage motors nearby, this isolation ensures that temperature readings from a digester (measured via Type J thermocouples) remain stable, even during motor startup. The module’s open thermocouple detection immediately alerts operators to broken sensor wires, preventing unmonitored process conditions.

Typical application scenarios

In a glass manufacturing plant’s melting furnace control system, TC625 plays a critical role in temperature regulation:

• 4 channels monitor furnace wall temperatures using Type S thermocouples (up to 1600°C), ensuring even heat distribution to prevent glass defects.
• 2 channels measure molten glass exit temperatures with Type R thermocouples, providing feedback for adjusting burner intensity.
• 2 channels track cooling zone temperatures via Type K thermocouples, optimizing annealing to reduce internal stresses.

Paired with AO910 analog output modules, the system forms closed-loop control, with TC625 providing real-time temperature data to the AC800M controller, which adjusts fuel valves and cooling fans accordingly.

In a food processing facility’s pasteurization line, TC625 ensures food safety compliance:

• Monitors 8 temperature points along the pasteurization tunnel using Type T thermocouples (-200°C to +350°C), covering both heating and cooling sections.
• Works with XVC769AE101termination units to organize wiring from thermocouples placed at different conveyor positions.
• Triggers alarms via connected safety modules if temperatures fall below the required 72°C, preventing under-processed products from reaching consumers.

The module’s fast response time (≤100 ms) ensures immediate detection of temperature drops, critical for maintaining food safety standards.

ABB TC625

Related model recommendations

• TC635: 16-channel thermocouple module that extends TC625’s capabilities in large-scale systems.
• RTD620: Resistance temperature detector (RTD) input module that complements TC625for applications requiring higher accuracy at lower temperatures.
• XVC769AE101: High-density termination unit that organizes thermocouple wiring for TC625.
• AO910: Analog output module that works with TC625in closed-loop temperature control systems.
• AC800M PM864: Controller that processes temperature data from TC625to execute control strategies.
• TB820V2: Terminal base required for mounting TC625, with secure connections for thermocouple wires.
• CI840A: Profibus communication module that enables remote monitoring of TC625
• SPDSO14: Digital output module that pairs with TC625to trigger alarms or shutdowns based on temperature thresholds.

Installation, commissioning and maintenance instructions

Installation preparation

Before installing TC625, power off the S800 I/O rack and verify the mounting surface is clean and dry. Mount the TB820V2 terminal base on a 35 mm DIN rail, leaving 30 mm clearance for airflow. Use shielded thermocouple extension wire (matching the thermocouple type) to connect sensors to the module, ensuring proper polarity (positive to positive terminals). Ground the cable shield at the sensor end only to prevent noise pickup. Configure thermocouple types via the controller’s software, matching each channel to the connected sensor. Power the module via the S800 backplane, ensuring 24 V DC supply is within ±10% tolerance.

Maintenance suggestions

Inspect TC625 monthly by checking power and channel status LEDs—steady green indicates normal operation, while red LEDs signal faults like open thermocouples. Calibrate the module annually using a precision temperature calibrator, verifying accuracy across the operating range of connected thermocouples. Clean terminal connections quarterly with a soft brush to remove dust. If a channel fails, swap the thermocouple to a spare channel to isolate the issue—replace TC625 with an ABB-approved spare if internal faults are confirmed, ensuring the replacement is configured with identical thermocouple types and compensation settings.

Service and guarantee commitment

The TC625 is backed by a 3-year warranty, covering defects in materials and workmanship under normal operating conditions. ABB’s process control technical support team provides 24/7 assistance for installation, calibration, and troubleshooting, including guidance on integrating with thermocouples, termination units like XVC769AE101, and control modules such as AO910.

Customers receive access to detailed calibration procedures, thermocouple wiring diagrams, and application notes specific to TC625. ABB offers factory calibration services for critical applications, ensuring traceability to international standards. With global distribution centers, replacement TC625 modules are available for rapid delivery, minimizing downtime in temperature-critical processes. Trust TC625 to deliver accurate temperature measurement, backed by ABB’s expertise in industrial automation.